KR19990076630A - Pattern-Non-bonded Nonwoven Web and Method of Making the Same - Google Patents

Abstract

The present invention relates to a pattern-unbonded nonwoven having a continuous bond region that defines a number of discontinuous unbonded regions suitable for use as an improved loop fixation material for hook-loop fastening systems. The fibers or filaments in the discontinuous unbonded regions of the present invention are dimensionally stabilized by continuous bonded regions comprising or surrounding each unbonded region. The spacing between the fibers or filaments in the unbonded area is large enough to accommodate and use hook elements of complementary hook material. The hook material may be any of a wide range of commercially available hook components that generally include a base material from which a number of hook elements are produced. The present invention also provides a continuous pattern of land regions that provide a nonwoven or web, wherein at least one of the two rolls, in which they are arranged in opposing manner and defined by a wedging between them, is heated and defines a number of discrete openings, pupils or holes. Providing a first calendar roll and a second calendar roll having a bonding pattern on the outermost surface thereof, the method including passing the nonwoven or web into the saw formed by the roll; A method for the production of pattern-unbonded nonwovens.

Description

Pattern-Non-bonded Nonwoven Web and Method of Making the Same

Mechanical fastening systems, otherwise referred to as hook and loop fastening systems, have become increasingly popular in many consumer and industrial applications. Examples of such applications include personal safety disposable absorbent articles. Typically, the hook and loop fastening system is used where resilient connections between two or more materials are required. This mechanical fixation system has in many cases replaced other traditional devices used to make releasable connections such as buttons, buckles, zippers, and the like.

Mechanical fixation systems typically use two components: a male (hook) component and a female (loop) component. It generally includes a plurality of semi-rigid hook-shaped members that are located or connected to the hook base material. The loop generally includes an elastic backing material from which a number of upright loops protrude. The hook-shaped member of the hook component is designed to engage the loop of the loop material, thereby forming a mechanical bond between the hook and loop of the two components. This mechanical coupling serves to prevent the separation of each component during normal use. The mechanical fixation system is applied by shear or shear stress, which is applied to the plane defined by the connected surface parallel to or connected to the connected surface of the hook and loop components as well as the peeling force or peel stress. It is designed to avoid separation of the hook and loop components. However, applying a force of ejection in a generally perpendicular or perpendicular rectangle to a surface defined by the connected surfaces of the hook and loop components, for example, destroys the loop member and thereby releases the engaged hook member or causes the loop member to The hook member can be separated from the loop member by bending the elastic hook member until detachable.

Mechanical fixation systems can be advantageously used in disposable personal safety absorbent articles such as disposable diapers, disposable garments, disposable incontinence products, and the like. Such disposable products are generally discarded after a relatively short period of use—usually hours—and are single-use items that are not cleaned and intended for reuse. As a result, in the design of such products it is desirable to avoid the components of the dead. Thus, to the extent that hook and loop components are used in such products, the hook and loop components need to be relatively inexpensive both in terms of the materials used and the manufacturing process of the components. On the other hand, in order to avoid a situation that may potentially embarrass the wearer, which may result from the detachment or detachment of the hook and loop components too early, the hook and loop components may be subjected to the proper wearing of the absorbent article. There must be sufficient structural stability and elasticity to withstand the forces applied thereto.

US Pat. No. 4,761,318 to Haute et al. Discloses loop fastening materials useful in mechanical fastening systems for disposable articles. The loop fastening material disclosed in this patent is a thermoplastic bonded to a second surface of a fibrous layer having a plurality of loops on a first surface selected to be releasably connected by a pair of hook fastenings and a fiber structure opposite the first surface. Resin layer. Thermoplastic resins settle in loops of fibrous structure.

No. 5,032,122 to Noel et al. Discloses loop fastening materials useful for mechanical fastening systems of disposable articles. The loop fixing material disclosed by this patent includes a backing of the deflective material and a fibrous member extending from the backing. The fibrous member is formed by a plurality of continuous filaments disposed on and intermittently fixed on the backing when the deflective material of the backing is in dimensional instability. The fibrous member is formed by shearing of fibers between the bonds to the backing, which are spaced and fixed when the deflective material is brought into a dimensional stable state to shrink or collect along its reaction path. Accordingly, the loop material of this patent requires a backing of a deflectable material, such as an elastomeric or elastomeric or heat shrinkable material, which transitions from a dimensional stable state to a dimensional unstable state and back to a dimensional stable state.

Goolite's U. S. Patent No. 5,326, 612 discloses another loop securing material useful for mechanical securing systems of disposable articles. The loop fastening material disclosed by this patent includes a nonwoven web secured to a backing. The nonwoven web accepts and hooks a hook of complementary hook components. The nonwoven web has a specific basis weight in the range of about 5 to 42 g / m ² , less than about 10% interfiber bonding area, and less than about 35% overall planar bonding area.

Despite the teachings of the documents mentioned above, there is still a need for improved loop fastening materials, particularly for mechanical fastening systems such as those used in disposable personal care absorbent articles. The pattern-unbonded nonwoven looplock material of the present invention is soft and cloth-like and therefore aesthetically appealing in appearance and feel. The pattern-unbonded nonwovens of the present invention have sufficient structural stability and dimensional stability so that, unlike the loop materials of the prior art, there is no need to attach to the support or backing layer to fix the fibers or filaments in the nonwoven. The pattern-unbonded nonwoven of the present invention is particularly satisfactory and comparable to traditional loop fastening materials when used with commercially available hook fastening materials when compared to traditional loop materials formed by knitting, warp knitting, weaving and the like. Or relatively cheaper creation of improved peel and shear strength.

Summary of the Invention

The present invention relates to a nonwoven fabric having a continuous bonding region that defines a number of discontinuous unbonded regions, suitable for use as an improved loop fixing material for hook and loop fixing systems. The fibers or filaments in the discontinuous unbonded regions of the present invention are dimensionally stabilized by continuous bonded regions that surround or enclose each unbonded region so that no support or backing layer of film or adhesive is required. The unbonded region is specifically designed to provide a spacing between fibers or filaments in the unbonded region that are sufficiently open or large enough to receive and engage a hook member of complementary hook material. The hook material can be any of a wide range of commercially available hook components that typically include a base material with a plurality of hook members protruding, as known in the art.

The pattern-unbonded nonwoven or web may be, for example, a spunbond nonwoven web formed of a single component or multicomponent meltspun filament. At least one surface of the nonwoven fabric includes a plurality of discontinuous unbonded regions surrounded or surrounded by continuous bonded regions. The continuous bonding region is nonwoven by joining or fusing the fiber or filament portions to each other extending from the outside of the unbonded region in the unbonded region to the inside of the bonded region while leaving the fibers or filaments in substantially no bond or fusion. Dimensionally stabilize the fibers or filaments that formed the web. The extent of bonding or fusion within the bonding region preferably leaves the nonwoven web in the bonding region, leaving the fiber or filament in a non-bonding region that serves as a "loop" for receiving and engaging the hook member protruding from the hook material. It is enough to make it non-fibrous in the inside. Since each discontinuous unbonded region is completely bound by the bond region, the fiber or filament in the unbonded region will generally have at least one portion made of it and advantageously have multiple portions made thereof, extending into the bond region. As a result, the unbonded fibers or filaments in each unbonded region serving as a "loop" are less detached from the fibrous nonwoven web structure when the hook member of the hook material is detached or pulled during normal use of the hook and loop fastening system. Or pulled out. Thus, the pattern-unbonded nonwoven material of the present invention, when used as a loop material, reduces the number of unattached, loose or unbound fibers or filaments in the loop material, thereby reducing the " pull-out " Provides a reduction. The pattern-unbonded nonwoven loop material exhibits improved surface structure and durability without otherwise adversely affecting the functionality of the nonwoven loop material in terms of coating and shear strength.

Other embodiments of the pattern-unbonded nonwovens or webs described above are laminates of two or more nonwovens or webs having different basis weights or different shapes and fiber sizes of the fibers in forming each nonwoven web or layer, and And a laminate of one or more nonwoven webs and one film layer.

A method suitable for forming the pattern-unbonded nonwoven material of the present invention provides a nonwoven or web, wherein at least one of the first and second calender rolls is heated and a plurality of discrete openings, apertures or holes. Providing a first and second calender rolls facing each other, having a bonding pattern on its outermost surface, including a continuous pattern of land regions defining a) and defining a fin between the two rolls; Passing a web into the fin formed by the roll. Each opening in the roll or rolls defined by the continuous land area forms a discontinuous unbonded region within at least one surface of the nonwoven or web where the fibers or filaments of the web are substantially or completely unbonded. In other words, the continuous pattern of land regions in the roll or rolls forms a continuous pattern of bonding regions that defines a plurality of discontinuous unbonded regions on at least one surface of the nonwoven or web. Another embodiment of the method includes pre-bonding the nonwoven or web or providing multiple nonwoven webs prior to passing the nonwoven or web into the bore formed by a calender roll to form a pattern-free bond laminate. It involves making.

When used as a loop component of hook and loop fastening systems for disposable personal care absorbent articles, the pattern-unbonded nonwoven loop material of the present invention is bonded or attached to the outer layer or backsheet of the article as a discrete piece of loop material. Can be. Alternatively, the pattern-unbonded nonwoven material may form a complete outer cover or backsheet of the disposable personal care absorbent article.

FIELD OF THE INVENTION The present invention relates generally to the fields of nonwovens and webs and methods of making the same. More specifically, the present invention relates to nonwovens and webs comprising continuous bonding regions that define a number of discrete, dimensionally stabilized unbonded regions. The nonwoven webs or webs made in accordance with the present invention are suitable for use as loop fastening materials for mechanical fastening systems, commonly referred to as hook and loop fastening systems.

1 is a front view of a pattern-unbonded nonwoven of the present invention.

FIG. 2 is a side cross-sectional view of the pattern-unbonded nonwoven of FIG. 1. FIG.

3 is a schematic side view of an exemplary process and apparatus for making a nonwoven fabric of spunbond bicomponent filaments.

4 is a schematic side view of a process and apparatus for making a pattern-unbonded nonwoven of the present invention.

5 is a partial perspective view that may be used in accordance with the process and apparatus of FIG. 4.

6 is a perspective view of a disposable diaper having a pattern-unbonded nonwoven loop material of the present invention as a loop piece.

The present invention relates to nonwovens or webs having continuous bonding regions that define a number of discontinuous unbonded regions, suitable for use as an improved loop fixing material for mechanical or hook and loop fastening systems. For purposes of illustration only, the present invention will be described as a loop fastening material that uses, independently or in combination, disposable disposable absorbent articles including diapers, sportswear, incontinence garments, sanitary napkins, bandages, and the like. The invention is not intended to be limited to these specific uses, as the invention is intended to be used in any application in which the pattern-unbonded nonwoven or web is suitably used.

For example, the pattern-unbonded nonwoven or web of the present invention may be used as a filtration material as well as a fluid conditioning or dispensing material for personal protective absorbent articles such as bodyside liners or surge materials used in disposable diapers and the like. have. The continuous bonding region of the pattern-unbonded nonwoven web is practically fluid impermeable, while the discrete non-bonding region in the web remains fluid permeable. Thus, the pattern-unbonded web includes discrete or isolated unbound regions that serve as specific fluid flow points or channels. The combination of continuous and discontinuous unbonded regions in the pattern-unbound web can be used to regulate and channel fluid flow. Further, the pattern of continuous and discontinuous regions may be modified to provide various desirable alignments of flow points or channels for fluid filtration, regulation or distribution by modifying the pattern-unbonded combination, as described in detail herein. Can be. In addition, the three-dimensional surface topography of the pattern-unbonded nonwoven of the present invention can provide its user with an aesthetically pleasing appearance.

The loop material of the present invention can be used with a wide range of hook materials when used as a magnetic or loop component of hook and loop fastening systems. Typical examples of hook materials suitable for use with the loop material of the present invention include the trade names CFM-22-1097, CFM-22-1121, CFM-22-1162, CFM-25-1003, CFM of Velcro Group of Manchester, New Hampshire. -29-1003 and CFM-22-1005 or Minnesota Mining and Minnesota Mining & In general, suitable hook materials may include about 16 to about 620, or about 124 to about 388, or about 155 to about 310 hooks per centimeter. Suitably the hook has a height of about 0.00254 centimeters to about 0.19 centimeters or about 0.0381 centimeters to about 0.0762 centimeters.

As is known in the art, the hook material typically includes a base layer having a plurality of unidirectional or bidirectional hook materials extending generally vertically therefrom. As used herein, the term "bidirectional" means a hook material having adjacent each hook member biased in the opposite direction from the longitudinal direction of the hook material. On the other hand, the term "unidirectional" refers to a hook material having adjacent each hook member deflected in the same direction in the longitudinal direction of the hook material.

To illustrate the pattern-unbonded nonwoven loop material of the present invention, the measurement data included below was obtained using a single type of hook material. This hook material comprises a hook member having an average overall height measured from the top of the base material to the highest point of the hook member. The average height of the hook members used in connection with the present invention is about 0.5 millimeters. This hook material has a hook density of about 265 hooks per centimeter. The base material is about 3.5 mils thick. This hook material is available from Velcro USA as CFM-29-1003. Other dimensions and properties of the hook material are as outlined in the examples below.

Although the term "hook material" is used herein to mean a part of a mechanical fixation system having an interlocking (hook) member, it is not intended to be limited to the form of an interlocking member comprising only "hook" and is bidirectional, unidirectional. However, it will include any form or shape of the interlocking member, such as the pattern-unbonded nonwoven loop material of the present invention, which is known or modified to hit the complementary loop anchor material in the art.

1 and 2 illustrate one embodiment of the pattern-unbonded nonwoven loop material 4 of the present invention. By definition, the term " pattern-unbonded nonwoven loop material " as used herein is in its simplest form a nonwoven or web having a continuous bond region 6 defining a plurality of discontinuous, dimensionally stabilized unbonded regions 8 It is intended to mean a loop or magnetic member for a hook and loop fastening system comprising a. The fibers or filaments of the nonwoven or web in the non-bonded region 8 are substantially or completely free of bonds or fused or retain their fibrous structure, while the fibers or filaments of the nonwoven web in the continuous bonded region 6 Completely bonded or fused to each other and preferably non-fibrous. This term is not intended to limit the loop material of the present invention to nonwoven materials only. Rather, the loop material of the present invention can be advantageously used in other embodiments where, for example, a pattern-unbonded nonwoven or web is attached or bonded to one layer of film material. The term "loop" is not intended to limit the loop material of the present invention to materials in which discontinuous, independently formed loop material is used to receive and engage hook members of complementary hook material. Rather, the loop material of the present invention includes a fibrous nonwoven or web that serves to engage the hook member without the individual fibers or filaments being formed into discrete loops.

The term "layer" or "web" as used herein may have the dual meaning of a single member or a plurality of members when used in the singular. The term "laminate" as used herein means a composite material made from two or more layers or webs of materials attached or bonded to each other.

Referring again to FIGS. 1 and 2, the pattern-unbonded nonwoven loop material 4 may generally be described as any nonwoven or web suitable for receiving and hooking a hook of complementary hook material when formed in accordance with the present invention. . As used herein, the term "nonwoven fabric" or "nonwoven web" refers to a web having a structure of individual fibers or filaments sandwiched therebetween, but not by means that can be identified as in knitted fabrics. . However, although the present invention is described with respect to nonwovens and webs, woven fabrics and / or knitted fabrics formed of suitable materials that allow a pattern of continuous bonding regions to define a plurality of non-bonding regions can be formed on at least one surface thereof. It can be dimensionally stabilized using the methods and apparatus described herein.

Commercially available thermoplastic polymer materials can be advantageously used to produce fibers or filaments that form the pattern-unbonded nonwoven material 4. The term "polymer" as used herein includes, but is not limited to, homopolymers and copolymers such as block, graft, random and alternating copolymers, terpolymers, and the like, or blends or modifications thereof. In addition, unless specifically limited otherwise, the term "polymer" shall include all possible geometrical arrangements of materials including, but not limited to isotactic, syndiotactic and random symmetry. As used herein, the term "thermoplastic polymer" or "thermoplastic polymer material" refers to a long chain polymer that softens when exposed to heat and returns to its original state when cooled to room temperature. Typical examples of thermoplastics include, but are not limited to, poly (vinyl chloride) s, polyesters, polyamides, polyfluorocarbons, polyolefins, polyurethanes, polystyrenes, poly (vinyl alcohols), caprolactam and copolymers thereof. Include. The fibers or filaments used to make the pattern-unbonded nonwoven material 4 may have any suitable shape and are hollow, solid, straight or crimped, as is well known in the art. Bicomponent or multicomponent fibers or filaments, which are constituents, bicomponent or multicomponent, and blends or mixtures of the foregoing fibers and / or filaments.

Nonwoven webs that can be used as the pattern-unbonded nonwoven material of the present invention can be formed by a wide variety of known forming methods including spunbonding, airlaying or bonded carded web forming methods. All such nonwovens may be temporarily bonded using known nonwoven bonding techniques, and may subsequently be joined using the pattern-unbonding methods and apparatus of the present invention, or alternatively the nonwoven web may be the pattern-unbonding method of the present invention. And can only be combined using the device.

Spunbond nonwoven webs can be made from melt spun filaments. As used herein, the term “melt-spun filament” refers to a number of thin, typically circular, rapidly reducing diameters of extruded filaments, for example, by undrawn or withdrawn fluid-stretching or other well known spunbonding mechanisms. By small diameter fibers and / or filaments formed by extruding molten thermoplastic material as filaments from the capillary of the radiation exposure. Spunbond nonwoven webs include U.S. Pat. No. 4,340,563 to Frontel et al., U.S. Pat.No. 3,692,618 to Dorschner et al., U.S. Pat.No. 3,802,817, Kinky et al. US Pat. Nos. 3,338,992 and 3,341,394, Hartman's US Pat. No. 3,502,763, Levi's US Pat. No. 3,276,944, Peterson's US Pat. The melt-spun filaments formed by the spunbond process are generally continuous and have a diameter of greater than 7 microns, more particularly about 10-30 microns. Another frequently used expression with respect to fibers or filaments is denier, defined as grams per 9000 meters of fiber or filament. The spunbond filaments are typically deposited on a flowable porous belt or forming wire, which is where the web is formed. Spunbond filaments are generally not tacky when deposited on a collecting surface.

Spunbond fabrics are generally stabilized and firm (combined) in some way as soon as they are made to give the web sufficient structural to withstand the toughness of further processing into a finished product. This stabilization step can be carried out by using an adhesive applied to the filament as a liquid or powder that can be thermally activated, or more generally using a consolidation roll. The term "consolidation roll" as used herein provides the web with sufficient structural properties for further processing, rather than relatively strong bonding of secondary bonding processes such as through-air bonding, thermal bonding, ultrasonic bonding, and the like. In order to do this, it is meant a set of rollers above and below the web used to consolidate the web in a manner of treating molten spun filaments, in particular spunbond webs, which have just been produced. The compaction roll slightly compresses the web to enhance its structure by enhancing the self adhesion of the web.

As described in detail in US Patent Application No. 362,328, filed Dec. 22, 1994, which is incorporated herein by reference, another means for performing the temporary bonding step uses a hot air knife. In short, the term "hot air knife" is not a relatively strong secondary bonding process as mentioned above, but in order to provide sufficient structure to the web for further processing, i.e., of the web It refers to a method of temporarily bonding the molten filament produced immediately, in particular the spunbond web, to enhance the ductility. The hot air knife generally concentrates a stream of very high flow rate of heated air, from about 300 to about 3000 meters per minute, more particularly from about 900 to about 1500 meters, towards the nonwoven immediately after its formation. The air temperature is generally from about 90 degrees Celsius to about 290 degrees Celsius, which is generally in the range of the melting point of at least one of the polymers in the web relative to the thermoplastic polymer used for spunbonding. Control of air temperature, speed, pressure, volume and other factors helps to avoid damage to the web while enhancing the structure of the web. The centralized air stream of the hot air knife may be configured to cover the web of heated air having a width of about 3 to 25 millimeters, particularly about 9.4 millimeters, which is operated substantially transverse to the substantially full width of the web. Aligned and controlled by one or more slots that serve as exit outlets. In other embodiments, there may be a plurality of slots arranged next to each other or separated at a slight interval. At least one slot is generally, but not necessarily, continuous and may consist of, for example, closely isolated holes. The hot air knife has a plenum that distributes and contains the heated air before discharging the heated air into the slot. The filling pressure of the hot air knife is generally about 2 to about 22 millimeters of mercury, and is disposed between about 6.35 to 254 millimeters and more particularly about 19.05 to about 76.20 millimeters on the molding surface. In a particular embodiment, the cross sectional area of the hot air knife fill space (ie, the cross sectional area of the longitudinal fill space) for the lateral flow of the hot air knife is at least twice the total slot exit area. Since the porous wire, from which the spunbond polymer is formed, generally travels at high speeds, the exposure time for the air emissions from the hot air knife of any particular portion of the web is subject to a longer period of time in the aeration bonding process. In general, it is less than about one tenth of a second and about one hundredth of a second. The hot air knife process is characterized in that the heated air process has several factors including air temperature, speed, pressure and volume, slot or hole alignment, density and size, and spacing separating the hot air knife filling space from the web. Have extensive variability and control over

The spunbond process can also be used to form bicomponent spunbond nonwoven webs, such as, for example, resulting from parallel (or cladding / nucleus) linear low density polyethylene / polypropylene spunbond bicomponent filaments. Suitable methods for forming the bicomponent spawnbond nonwoven webs are described in US Pat. No. 5,418,045 to Piqué et al., Which is hereby incorporated by reference in its entirety. 3, the process line 10 for forming the bicomponent filaments and the resulting webs independently spins both polyethylene and polypropylene from the hoppers 14 (a) and 14 (b), respectively. The use of a pair of extruders 12 (a) and 12 (b) to feed exposure 18. Radiation exposure for producing bicomponent filaments is well known in the art and therefore is not described in detail herein. In general, the radiation exposure 18 includes a plurality of vertically stacked plates, each having a form of aperture aligned to create a flow path for high melting point and low melting point polymers to be directed to the fiber forming opening in the radiation exposure. It includes a mold containing a spinning pack. The radiation exposure 18 has openings arranged in one or more rows and the openings form a filament film extending downward when a polymer is extruded through the radiation exposure. When the filament film exits the radiation exposure 18, it is contacted by a quench gas from one or both sides of the filament film (not shown), which at least partially quenchs the filament and exposes the radiation exposure 18. This creates a potential spiral crimp in the filament extending from the. Typically, the quench gas will be directed generally perpendicular to the length of the filament at a speed of about 30 to about 120 meters per minute and a temperature of about 7 degrees to about 32 degrees Celsius.

A fiber drawing unit or inhaler 22 is disposed below the radiation exposure 18 to receive the quenched filaments. Fiber drawing units or inhalers for use in melt spinning polymers are well known in the art as described above. Typical fiber drawing units suitable for use in the method are linear fiber inhalers of the type disclosed in US Pat. No. 3,802,817 to Machuki et al., And US Pat. No. 3,692,618 to Dorschner et al. And US Pat. Including an eductive gun, the entirety of which is hereby incorporated by reference. The fiber drawing unit 22 generally has one elongated passageway through which the filaments are drawn from the passageway by drawing gas flow through the passageway. The intake gas can be any gas, such as air, that does not act negatively with the polymer of the filament. The heater 24 supplies the hot suction gas to the fiber stretching unit. When the intake gas draws the quenched filament and ambient air through the fiber drawing unit 22, the filament is heated to the temperature necessary to activate the potential crimp. The temperature required to activate the potential crimp in the filament will range from about 43 degrees Celsius up to a low melting point component polymer, in this case lower than the melting point of the polyethylene. In general, the higher the air temperature, the greater the number of crimps produced per unit length of filament. Optionally, the filament film exiting the radiation exposure 18 can be stretched at room temperature, resulting in a substantially straight or crimp-free spunbond filament web.

The stretched and crimped filaments exit the fiber stretching unit 22 and are generally supported by a vacuum device 30 located below the forming surface and are deposited on the continuous forming surface 26 in a random manner. The purpose of the vacuum is to remove undesired scattering of the filaments and lead the filaments onto the forming surface 26 to form a uniform, non-bonded nonwoven web of bicomponent filaments. If desired, the resulting web may be slightly compressed by a compression roller 32 or a hot air knife (not shown) before the web is applied to the pattern-unbound combination 34 of the present invention as described below.

Suitable nonwoven webs used to achieve the present invention can also be made from bonded carded webs and airlaid webs, which are typically formed of discontinuous, staple fibers. The use of the nonwoven web in the manufacture of the patterned unbonded nonwoven loop material of the present invention has at least one portion and advantageously multiple portions, discontinuous in order to maximize the number of individual fibers in the unbonded region extending to the bonded region. However, care must be taken to suitably adapt the size and density of the unbonded regions.

Bonded carded webs are generally made from staple fibers, which are purchased as scoops. The nest is placed in a pulling machine to separate the fibers. The fibers are then sent through a combing or carding unit to further separate and align the staple fibers longitudinally to form a generally deflected fibrous nonwoven web. Once the web is formed, the web can be temporarily bonded as described above.

Airlaying is another well known method of forming fibrous nonwoven webs. In the airlaying process, small fiber bundles having typical lengths in the range of about 6 to 19 millimeters are separated and attracted to the air feeder, which is generally aided by a vacuum feeder and then deposited on the forming screen. The randomly deposited fibers can then be bonded to each other by known bonding techniques.

After the nonwoven web is formed, the temporarily bonded or unbonded web is passed through a method and apparatus suitable for forming the pattern-unbonded nonwoven loop material of the present invention. Referring now to FIGS. 4 and 5, a method and apparatus for forming the pattern-unbonded nonwoven loop material of the present invention will be described. In FIG. 4, an apparatus for forming the pattern-unbonded nonwoven loop material of the present invention is generally represented by member 34. The apparatus includes an unrolled first web 36 for the first web 38. Optionally, one or more additional (not shown) loose webs 37 for the additional web or layer 39 may be used to form the multilayer pattern-unbonded laminate. Although the device shown in FIG. 4 shows a loose web 36, the pattern-unbonded combination 40 can be placed in a continuous (serial) process with the nonwoven forming device described herein as shown in FIG. 3. The term "pattern-non-binding combination" as used herein should not be interpreted as a device for breaking, breaking or removing bonds present in the web 38. Rather, the pattern-binding combination continuously joins or fuses fibers or filaments that form the webs 38 in certain areas of the web, and in other particular areas of the webs, joins or filaments of fibers or filaments of the webs 38. Means a device to prevent fusion. Herein, the region means a bonding region and a non-bonding region, respectively.

The first web 38 (or simply " web " if the only one being unrolled) is used is a pattern comprising a first or pattern roll 42 and a second or anvil roll 44 away from the unwinding 36. It is passed through a non-binding combination. The two rolls are driven by traditional drive means, for example electric motors (not shown). Pattern roll 42 is a fully circular cylinder that can be formed of a suitable durable material such as, for example, steel so that wear in use is reduced. The pattern roll 42 has a pattern of land regions 46 defining a plurality of discrete openings or pupils 48 at its outermost surface. The land area 46 is designed to form a fin with a smooth or flat outer surface of the opposedly placed anvil roll 44, which is also a fully circular cylinder that may be formed of a suitable durable material.

The size, shape, number and arrangement of the openings 48 of the pattern roll 42 can be varied to meet the particular end use requirements of the pattern-unbonded nonwoven loop material formed thereby. In order to reduce the occurrence of fiber pull-out in the final loop material, the size of the opening 48 in the pattern roll 42 reduces the likelihood that the entire length of the filaments or fibers forming the unbonded region is within a single unbonded region. Should be dimensioned. In other words, the fiber length should be chosen to reduce the likelihood that the entire length of a given fiber or filament falls within a single unbonded region. On the other hand, the desirability of the size limitation of the opening 48 in the pattern roll 42 and the unbonded region 8 formed thereby in the pattern-unbonded nonwoven loop material 4 are complementary to the hook member of the hook material. It is checked against each other by the need that the unbonded regions 8 have a sufficient size in order to provide the necessary engagement regions for the purpose. Having an average diameter of about 0.127 to about 0.635 centimeters, more specifically about 0.330 to about 0.406 centimeters, and a depth measured from the outermost surface of the pattern roll 42 at least about 0.051 centimeters, more particularly about 0.152 centimeters or more Circular openings 48 as shown in 5 are believed to be suitable for forming the pattern-unbonded nonwoven material of the present invention. Although the openings 48 in the pattern roll 42 as shown in FIG. 5 are circular, other shapes such as ellipses, rectangles, diamonds, and the like may be advantageously used.

It is also possible to select the number of densities of the openings 48 in the pattern roll 42 without severely limiting the size of the continuous engagement area to increase the incidence of fiber pull-out to provide the required amount of engagement area of the hook member. Pattern rolls having an opening density of about 1.0 to 25 openings per square centimeter can be advantageously used to form the pattern-unbound loop material of the present invention.

Moreover, without excessively reducing the portion of the pattern-unbonded loop material occupied by the continuous bond regions that serve to reduce fiber pull-out, the spacing between each opening 48 is the hook of the final pattern-unbonded loop material. It may be selected to enhance the engagement function. Inter-gap spacings suitable for the presented embodiments can be from about 3.30 to about 5.59 millimeters in the centerline to centerline, longitudinal and transverse directions. As used herein, the term "machine direction" or MD means the length of the material or fabric in the direction in which the material or fabric is produced (from left to right in FIG. 3). The term "cross-machine direction" or CD refers to the width of the material or fabric, ie, generally perpendicular to the MD.

It is believed that the particular alignment or arrangement of the openings 48 in the pattern roll 42 is not critical, so long as the desired level of surface structure and durability, together with the opening size, shape and density, and hook member engagement are achieved. For example, as shown in FIG. 5, each opening 48 is aligned in staggered rows (see FIG. 1). Other arrangements are contemplated within the scope of the present invention.

In order to satisfy the end-use application of the pattern-unbonded material, the outermost surface portion of the pattern roll 42 occupied by the continuous region 46 can likewise be modified. The degree of bonding imparted to the pattern-unbonded nonwoven loop material by the continuous land region 46 is determined by the total planar area of at least one surface of the pattern-unbonded nonwoven loop material 4 occupied by the bonding region 6. It can be expressed as a% binding region meaning a part (see FIG. 1). Generally speaking, the minimum limit on the% bonding area suitable for forming the pattern-unbonded nonwoven loop material 4 of the present invention is the point where the fiber pull-out greatly reduces the surface structure and durability of the pattern-unbonded material. to be. The% binding area required is in the form of the polymeric material used to form the fibers or filaments of the nonwoven web, whether the nonwoven web is a single layered or multilayered fibrous structure, and the nonwoven web is the pattern-unbonded combination. It will be influenced by many factors, such as whether it is uncoupled or combined before it is passed through. Pattern-unbonded nonwoven web materials having a% binding area of about 25 to about 50%, more particularly about 36 to about 50%, have been found to be suitable.

The outer surface temperature of the pattern roll 42 can be changed by heating or cooling compared to the anvil roll 44. Heating and / or cooling may affect the characteristics of the web being processed and the degree of bonding of the single or multiple webs passing through the pins formed between the pattern rolls 42 and the anvil rolls 44 rotating in opposite directions. . In the embodiment shown in FIG. 4, both the pattern roll 42 and the anvil roll 44 are preferably heated to the same bonding temperature. The specific temperature range used to form the pattern-unbonded nonwoven loop material is formed between the pattern roll 42 and the anvil roll 44, in the form of the polymeric material used to form the pattern-unbonded material. It depends on several factors, including the injection or linear velocity of the nonwoven web passing through the fin and the pin pressure between the pattern roll 42 and the anvil roll 44.

The anvil roll 44 shown in FIG. 4 has a smoother, preferably smoother or flatter outer surface than the pattern roll 44. However, although the anvil roll 44 has a slight pattern on its outer surface, it may still be considered smooth or flat for the purposes of the present invention. For example, if the anvil roll 44 is made from or has a more flexible surface, such as a resin-infused surface or rubber, it will exhibit surface irregularities but will still be considered to be flexible or flat for the purposes of the present invention. will be. Such surface is here meant collectively "flat". The anvil roll 44 provides a substrate to the pattern roll 42 and the web or web of material in contact. In general, the anvil roll 44 will be made from a material such as steel or reinforced rubber, cotton treated with resin or polyurethane.

Alternatively, the anvil roll 44 may be replaced with a pattern roll (not shown) having a pattern of continuous land regions defining a number of discrete pupils or openings, as in the pattern roll 42 described above. In such a case, the pattern-unbonded combination is a pair of patterns that rotate in opposite directions to impart a pattern of continuous bond regions to both the upper and lower surfaces of the pattern-unbonded nonwoven loop material that define a plurality of discrete unbonded regions. Will include a roll. Rotation of the oppositely disposed pattern rolls can be synchronized such that the final unbound area on the surface of the pattern-unbound material is vertically aligned or juxtaposed.

4, the pattern roll 42 and the anvil roll 44 rotate in opposite directions to draw the nonwoven web (or web) through a fin region defined therebetween. The pattern roll 42 has a first rotational speed measured at its outer surface and the anvil roll 44 has a second rotational speed measured at its outer surface. In the embodiment shown, the first and second rotational speeds are substantially the same. However, the rotational speed of the pattern roll and the anvil roll can be changed to create a different speed between the rolls rotating in the opposite direction.

The position of the pattern roll 42 and the anvil roll 44 disposed to face each other may be changed to create a concave region 50 between the two rolls. The shock pressure inside the shock region 50 may vary depending on the nature of the web or the webs themselves and the degree of bonding desired. 요소 Other factors that will change the pressure include the form of the polymer used to form the pattern-unbonded nonwoven material as well as the temperature of the pattern roll 42 and the anvil roll 44 and the openings inside the pattern roll 42 ( Will cover the thickness and size of 48). With regard to the degree of bonding imparted to the pattern-unbonded nonwoven loop material inside the continuous bonding region, the pattern-unbonding material is preferably fully bonded or melt-fused in the bonding region so that the polymeric material is non-fibrous. . This high degree of bonding is important in stabilizing portions of the fibers or filaments in the unbonded regions that extend into the continuous bonded regions and reducing fiber pull-out when the hook member detaches from the discontinuous unbonded regions.

Once formed, the pattern-unbonded nonwoven web material of the present invention may be attached to an outer cover or backsheet of a personal protective absorbent article, such as the disposable diaper 60 shown in FIG. More specifically, a pattern-unbonded loop material is attached to the outer surface such that at least one surface of the pattern-unbound loop material has a pattern of continuous bond regions that define a plurality of discrete unbonded regions. The pattern-unbonded loop material may be secured to the outer cover 62 of the diaper 60 by known adhesive means, including adhesives, thermal bonds, ultrasonic bonds, or a combination of these means. A wide range of adhesives can be used, including but not limited to hot melt, pressure sensitive adhesives using water and solvents. Powdered adhesive can also be applied to the pattern-unbonded loop material and then heated to activate the powder adhesive to achieve a complete bond.

Diapers 60, which are typical of most personal protective absorbent articles, include a liquid permeable bodyside liner 64 and a liquid impermeable outer cover 62. Various woven or nonwoven fabrics may be used for the bodyside liner 64. For example, the bodyside liner may be comprised of a meltblown or spunbond nonwoven web of polyolefin fibers or a bonded carded web of natural and / or synthetic fibers. Outer cover 62 may typically be formed from a thin thermoplastic film, such as a polyethylene film. The polymeric film outer cover may be embossed and / or matte finished to provide an aesthetically pleasing appearance. Other configurations for the outer cover 62 include laminates formed of woven or nonwoven fibrous webs or wovens or nonwovens and thermoplastic films constructed or treated to impart the desired degree of liquid impermeability. Optionally, outer cover 62 may be comprised of a vapor or gas permeable, “breathable” material that is substantially impermeable to liquid but permeable to vapor or gas. Respiratory rate can be achieved by making the film respirable, for example, by using a filler in a film polymer formulation, extruding the filler / polymer formulation into a film and then stretching the film sufficiently to create voids near the filler particles. May be imparted within the polymer film. In general, the more filler used and the greater the elongation, the greater the respiratory rate.

For example, an absorbent nucleus 66 formed from a blend of hydrophilic cellulosic woodpulp fluff fibers and superabsorbent gelling particles (eg, superabsorbents) is disposed between the bodyside liner 64 and the outer cover 62. Absorbent nucleus 66 is generally compressible, compatible, does not cause irritation to the wearer's skin, and can absorb and retain liquid exudate from the body. For the purposes of the present invention, the absorbent nucleus 66 may comprise one single, complete material, or a plurality of respective independent materials. The size and absorbent capacity of the absorbent nucleus 66 should be compatible with the size of the intended user and the liquid load imposed by the intended use of the diaper 60.

Optionally, the elastic member may be disposed adjacent each longitudinal edge 68 of the diaper 60. The elastic member is aligned to stretch and hold the transverse, side edge 68 of the diaper 60 against the wearer's leg. In addition, the elastic member may also be disposed adjacent one or both of the distal edges 70 of the diaper 60 to provide an elasticized waistband.

The diaper 60 may further include an optional sealing flap 72 made or attached from the bodyside liner 64. Suitable construction and alignment for the sealing flap is incorporated herein by reference in its entirety. US Pat. No. 4,704,116 to Enol.

In order to secure the diaper 60 to the wearer, the diaper will have some form of securing means attached thereon. As shown in FIG. 6, the securing means is provided within the front waistband portion of the diaper 60 and the hook member 74 attached to the inner and / or outer surface of the outer cover 62 in the rear waistband portion of the diaper 60. Hook and loop fastening system comprising one or more loop members or patches 76 made from the pattern-unbonded loop material of the present invention attached to an outer surface of outer cover 62.

In describing this embodiment of the invention, a series of sample pattern-unbonded nonwoven loop materials were formed with the non-woven materials of the prior art to further illustrate the invention. These samples were tested to determine the peel strength and shear strength of the sample materials.

The peel strength of the loop material is a measure of its functionality. More specifically, peel strength is a term used to describe the amount of force required to pull down and drop the male and magnetic components of a hook and loop fastening system. One method of measuring the peel strength is to pull one component from another at a 180 degree angle.

Starch strength is another measure of the strength of hook and loop fastening systems. Shear field is measured by engaging male and magnetic components and applying a force to separate the two components along a plane defined by the connected surface.

The test method used to evaluate each sample of the pattern-unbonded nonwoven loop material of the present invention is presented below.

<Test method>

Basis weight

Base weights of the various materials described herein were determined in accordance with Federal Test No. 191A / 5041. The sample size of the sample material was 15.24 x 15.24 centimeters and averaged after three values were obtained for each material. The values reported below are averages.

bulk

The bulk of the sample material, the basis of thickness, was measured with a Starret type tester at 0.5 psi.

180 degree peeling strength test

The 180 degree peel strength test is performed by attaching the hook material to the loop material of the hook and loop fastening system and then removing the hook material from the loop material at a 180 degree angle. The maximum load required to desorb the two materials is expressed in grams.

To carry out the test, Sintech Inc. has a sales office in North Carolina Research Trial Park. There is a need for a continuous rate extension tension tester with a maximum scale load of 5000 grams, such as the company's commercially available Sintech System 2 computer mounted test system. A sample of loop material 75 millimeters wide and 102 millimeters long is placed on a flat, adhesive support surface. A sample of hook material secured with adhesive and ultrasonically to a substantially inelastic nonwoven material, 45 millimeters wide and 12.5 millimeters long, is placed and processed over the top surface of the loop material sample. In order to properly and evenly engage the hook material with the loop material, the 2.0412 kilogram hand roller is rotated for one cycle, such as the forward and reverse strokes of the hand roller over the combined hook and loop material. The end of the loop material towards the upper jaw is folded down and fixed in the lower jaw of the tension tester, while one end of the fingertab material supporting the hook material is fixed to the upper jaw of the tension tester. Prior to operating the tension tester, the positioning of each material in the tension tester should be adjusted such that there is a minimum sag in each material. The hook member of the hook material is deflected in a direction generally perpendicular to the predetermined direction of motion of the tension tester jaw. The tensile tester operates at a crosshead speed of about 500 millimeters per minute and then records the grams of peak load required to detach the hook material from the loop material at a 180 degree angle.

Dynamic shear strength test

The dynamic shear strength test is performed by engaging the hook material with the loop material of the hook and loop fastening system and then pulling the hook material across the surface of the loop material. The maximum load needed to detach the hook from the loop is expressed in grams.

To conduct the test, Sintech Inc. has a greenery in North Carolina Research Trial Park. There is a need for a continuous rate extension tension tester with a maximum scale load of 5000 grams, such as the company's commercially available Sintech System 2 computer mounted test system. A sample of loop material 75 millimeters wide and 102 millimeters long is placed on a flat, adhesive support surface. A sample of hook material secured with adhesive and ultrasonically to a substantially inelastic nonwoven material, 45 millimeters wide and 12.5 millimeters long, is placed and processed over the top surface of the loop material sample. In order to properly and evenly engage the hook material with the loop material, the 2.0412 kilogram hand roller is rotated for one cycle, such as the forward and reverse strokes of the hand roller over the combined hook and loop material. One end of the nonwoven material supporting the hook material is fixed to the upper jaw of the tension tester, and the end of the loop material towards the lower jaw is fixed to the lower jaw of the tension tester. Prior to operating the tension tester, the positioning of each material in the tension tester should be adjusted such that there is a minimum sag in each material. The hook member of the hook material is deflected in a direction generally perpendicular to the predetermined direction of motion of the tension tester jaw. The tension tester operates at a crosshead speed of about 250 millimeters per minute and then records the grams of peak load required to detach the hook material from the loop material.

Eighteen pattern-unbonded nonwoven loop materials and three comparative nonwoven materials are given below. The sample pattern-unbound material is designed to illustrate certain embodiments of the invention and to teach one of ordinary skill in the art how to practice the invention. Comparative Examples A to C are designed to illustrate the advantages of the present invention. All of the samples were formed using the methods and apparatus described herein and shown in FIGS. In forming each pattern-unbound material sample, a bicomponent spunbond web or laminate was passed through a saw formed between two oppositely rotating thermal bond rolls including a pattern roll and anvil roll. The outer surface of the pattern roll included a pattern of land regions defining a plurality of discrete openings. The land area occupied about 36% of the total area of the pattern roll outer surface. The openings in the pattern roll were circular, arranged in a wavy form, having an average diameter of 0.406 centimeters, a depth of 0.152 centimeters and a density of about 5 openings / cm ² . The centerline to centerline spacing between openings was 0.406 centimeters in the longitudinal direction and 0.483 centimeters in the transverse direction. The outer surface of the anvil roll was substantially smooth.

Comparative Examples A to C

As described in US Pat. No. 5,418,045 to Pike et al., Three single layer bicomponent spunbond nonwoven webs with different basis weights were formed of continuous melt spun, crimp bicomponent filaments. The polymeric constituents of the bicomponent filaments were present in a weight ratio of 50 to 50 in parallel arrangement. The bicomponent filaments had a substantially circular cross section. The polymer components are a) 98% polypropylene and 2% titanium dioxide (TiO ₂ ) from Exxon 3445 and b) 98% linear low density polyethylene (LLDPE) and TiO ₂ 2 from Dow 6811A. %, Where TiO ₂ means a concentrate consisting of 50% TiO ₂ and 50% polypropylene by weight. The cooling air temperature under the radiation exposure was about 15 degrees Celsius, and the drawn air temperature entering the fiber stretching unit was about 177 degrees Celsius. The bicomponent spunbond web was then thermally bonded to yield a point-bonded nonwoven material having a total bonding area of about 15%.

Example A

The single layer bicomponent spunbond nonwoven web of Comparative Example A was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. Both the pattern roll and the anvil roll were heated to a temperature of about 126 degrees Celsius. The shock pressure in the shock gap formed between the pattern roll and the anvil roll was about 28 kg / cm ² . After subjecting the materials of Comparative Examples A and A to the above described skin and shear measurements, the latter material had almost no loose filaments in the unbonded areas, which caused the fiber pull-outs resulting from the use of the present invention. To support the decline.

Example B

The single layer bicomponent spunbond nonwoven web of Comparative Example B was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. The pattern-unbonding processing conditions were the same as described in Example A above except that both the pattern roll and the anvil roll were heated to a temperature of about 128 degrees Celsius. After subjecting the materials of Comparative Example B and Example B to the above described skin and shear measurements, the latter material had little loose filaments in the unbonded area, which was due to the fiber pull-out resulting from the use of the present invention. To support the decline.

Example C

The monolayer bicomponent spunbond nonwoven web of Comparative Example C was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. Pattern-nonbonding processing conditions were the same as in Example A above. After subjecting the materials of Comparative Examples C and C to the above described epidermal and shear measurements, the latter material had little loose filaments in the unbonded areas, which caused the fiber pull-outs resulting from the use of the present invention. To support the decline.

Example D

Single layer bicomponent spunbond webs consisting of continuous melt spinning, crimp filaments were formed as described herein in US Pat. No. 5,418,045. The polymer constituents of the bicomponent filaments were the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after it was formed.

Single-layer bicomponent spunbond webs were formed of pattern-unbonded nonwoven loop material using the pattern-unbonded combinations described herein. Both the pattern roll and the anvil roll were heated to a temperature of about 132 degrees Celsius, and the pressure in the jar formed between the pattern roll and the anvil roll was about 49 kg / cm ² , and the linear velocity of the bicomponent spunbond web entering the jar was It was about 19 meters per minute.

Example E

The monolayer bicomponent spunbond nonwoven web was formed as described above in Example D and was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. The pattern-unbonding processing conditions were the same as described in Example D above, except that the linear velocity of the bicomponent spunbond web entering the fin was about 45 meters per minute.

Example F

As described in US Pat. No. 5,418,045, a two layer nonwoven laminate material was made using first and second bicomponent spunbond nonwoven webs formed of continuous melt spinning, crimp bicomponent filaments. The polymer constituents of the bicomponent filaments of each nonwoven layer were the same as in the above examples. In this example, the basis weight and size of the first and second bicomponent spunbond webs forming the bicomponent filaments were the same.

The first bicomponent spunbond nonwoven web was formed of a pattern-unbonded nonwoven layer using the pattern-unbonded combination described herein. Thereafter, a second bicomponent spunbond nonwoven web was formed and placed on top of the first pattern-unbonded nonwoven layer and the first and second nonwoven layers were laminated together by passing through the pattern-unbonded combination described herein. . Pattern-nonbonding processing conditions were the same as in Example D above.

Example G

As described in US Pat. No. 5,418,045, the two layer nonwoven laminate material is a continuous bispun spunbond, non-crimped bicomponent filament and a second bicomponent spunbond nonwoven web formed of a continuous meltspun, crimp bicomponent filament Minutes were made using a spunbond nonwoven web. The polymer constituents of the bicomponent filaments of each nonwoven web were the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after formation. In this example, the basis weights and sizes of the first and second bicomponent spunbond webs forming the bicomponent filaments were different.

The relatively low basis weight and small fiber size of the first bicomponent spunbond nonwoven web was formed into a pattern-unbonded nonwoven layer using the pattern-unbonded combination described herein. Thereafter, a second bicomponent spunbond nonwoven web of relatively high basis weight and large fiber size was formed and placed on top of the first pattern-unbonded spunbond nonwoven layer. The second bicomponent spunbond layer was temporarily bonded using a hot air knife placed about 38.1 millimeters above the exposed surface of the second spunbond layer. The hot air knife brought a stream of heated air to a temperature of about 211 degrees Celsius over the width of the spunbond web. Sufficient pressure of the hot air knife was about 2 mm with mercury. The first and second nonwoven layers were laminated to each other by passing through the pattern-unbonded combination described herein. The pattern-unbonding processing conditions were the same as described in Example D above except that the pattern roll and anvil roll were heated to about 128 degrees Celsius. When the peel and shear strength were measured, the second bicomponent spunbond nonwoven web was engaged with the hook member of the measurement hook material.

Example H

As described in US Pat. No. 5,418,045, single layer bicomponent spunbond nonwoven webs were formed of continuous melt spun, crimped bicomponent filaments. The polymer component of the bicomponent filament was the same as in the above examples. The bicomponent spunbond web was prebonded with a hot air knife disposed about 44.5 millimeters above the top surface of the bicomponent spunbond web. The hot air knife brought a stream of heated air to a temperature of about 211 degrees Celsius over the width of the spunbond web. Sufficient pressure of the hot air knife was about 2 mm with mercury. The bicomponent spunbond web was not thermally point bonded after it was formed.

The single layer bicomponent spunbond web was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. The pattern-unbonding processing conditions were the same as described in Example G above, except that the linear velocity of the bicomponent spunbond web was about 14 meters per minute.

Example I

As described in US Pat. No. 5,418,045, the two layer nonwoven laminate material is a continuous bispun spunbond, non-crimped bicomponent filament and a second bicomponent spunbond nonwoven web formed of a continuous meltspun, crimp bicomponent filament Minutes were made using a spunbond nonwoven web. The polymer component of the bicomponent filaments of each nonwoven layer was the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after it was formed. In this example, the basis weights and sizes of the first and second bicomponent spunbond webs forming the bicomponent filaments were different.

After the first bicomponent spunbond nonwoven web of relatively low basis weight and small fiber size is formed, the second bicomponent spunbond nonwoven web of relatively high basis weight and large fiber size is formed to form a top of the first pattern-unbonded nonwoven layer. Was placed on. The second bicomponent spunbond web was crosslinked as described above in Example G. The first and second nonwoven layers were then laminated together by passing through the pattern-unbonded combination described herein. Pattern-unbonded processing conditions were the same as in Example G above. When the peel and shear strength were measured, the second bicomponent spunbond nonwoven web was engaged with the hook member of the measurement hook material.

Example J

As described in US Pat. No. 5,418,045, the two layer nonwoven laminate material is a continuous bispun spunbond, non-crimped bicomponent filament and a second bicomponent spunbond nonwoven web formed of a continuous meltspun, crimp bicomponent filament Minutes were made using a spunbond nonwoven web. The polymer component of the bicomponent filaments of each nonwoven layer was the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after it was formed. In this example, the basis weights and sizes of the first and second bicomponent spunbond webs forming the bicomponent filaments were different.

After the first bicomponent spunbond nonwoven web of relatively low basis weight and small fiber size is formed, the second bicomponent spunbond nonwoven web of relatively high basis weight and large fiber size is formed to form a top of the first pattern-unbonded nonwoven layer. Was placed in. The second bicomponent spunbond web indicates that the hot air knife was placed about 27.0 millimeters above the exposed surface of the second nonwoven layer and brought the heated air stream to about 118 degrees Celsius across the width of the nonwoven web. Except for the crosslinking as described above in Example G. The first and second nonwoven layers were laminated together by passing through the pattern-unbonded combination described herein. The pattern-unbonded processing conditions were in Example G, except that the pattern roll and the anvil roll were heated to a temperature of about 138 degrees Celsius and the pressure in the jar formed between the pattern roll and the anvil roll was about 56 kg / cm ^2. Same as in. When the peel and shear strength were measured, the second bicomponent spunbond nonwoven web was engaged with the hook member of the measurement hook material.

Example K

As described in US Pat. No. 5,418,045, single layer bicomponent nonwoven webs were formed of continuous melt spun, crimped bicomponent filaments. The polymer constituents of the bicomponent filaments were the same as in the above examples. The bicomponent spunbond web was bonded with a hot air knife under the conditions set forth in Example J except that the hot air knife was placed at a distance of about 38.1 millimeters. The bicomponent spunbond web was not thermally point bonded after it was formed.

The single layer bicomponent spunbond web was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. The pattern rolls and anvil rolls were heated to about 127 degrees Celsius. The pressure in the paddle formed between the pattern roll and the anvil roll was about 49 kg / cm ² . The linear velocity of the bicomponent spunbond web entering the fin was about 13 meters per minute.

Example L

As described in US Pat. No. 5,418,045, the two layer nonwoven laminate material is a continuous bispun spunbond, non-crimped bicomponent filament and a second bicomponent spunbond nonwoven web formed of a continuous meltspun, crimp bicomponent filament Minutes were made using a spunbond nonwoven web. The polymer component of the bicomponent filaments of each nonwoven layer was the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after it was formed. In this example, the basis weights and sizes of the first and second bicomponent spunbond webs forming the bicomponent filaments were different.

After the first bicomponent spunbond nonwoven web of relatively low basis weight and small fiber size is formed, the second bicomponent spunbond nonwoven web of relatively high basis weight and large fiber size is formed to form a top of the first pattern-unbonded nonwoven layer. Was placed in. The second bicomponent spunbond web was temporarily bonded using a hot air knife under the conditions of Example K above. The first and second nonwoven layers were laminated together by passing through the pattern-unbonded combination described herein. The pattern rolls and anvil rolls were heated to a temperature of about 128 degrees Celsius. The pressure in the paddle formed between the pattern roll and the anvil roll was about 56 kg / cm ² . The linear velocity of the bicomponent spunbond entering the fin was about 13 meters per minute. When the peel and shear strength were measured, the second bicomponent spunbond nonwoven web was engaged with the hook member of the measurement hook material.

Example M

As described in US Pat. No. 5,418,045, the two layer nonwoven laminate material is a first bicomponent spunbond nonwoven web formed of continuous meltspun, uncrimped bicomponent filaments and a second isomer formed of continuous meltspun, crimp bicomponent filaments Minutes were made using a spunbond nonwoven web. The polymer component of the bicomponent filaments of each nonwoven layer was the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after it was formed. In this example, the basis weights and sizes of the first and second bicomponent spunbond webs forming the bicomponent filaments were different.

After the first bicomponent spunbond nonwoven web of relatively low basis weight and small fiber size is formed, the second bicomponent spunbond nonwoven web of relatively high basis weight and large fiber size is formed to form a top of the first pattern-unbonded nonwoven layer. Was placed on. The second bicomponent spunbond web was temporarily bonded using a hot air knife under the conditions in Example L above. The first and second nonwoven layers were laminated together by passing through the pattern-unbonded combination described herein. The pattern-unbonding processing conditions were the same as described in Example L above, except that the linear velocity of the bicomponent spunbond web entering the chop was about 21 meters per minute. When the peel and shear strength were measured, the second bicomponent spunbond nonwoven web was engaged with the hook member of the measurement hook material.

Example N

As described in US Pat. No. 5,418,045, single layer bicomponent spunbond nonwoven webs were formed of continuous melt spun, crimped bicomponent filaments. The polymer constituents of the bicomponent filaments were the same as in the above examples. The bicomponent spunbond web was bonded using a hot air knife under the conditions described above in Example K, except that sufficient pressure was about 2.6 millimeters of mercury. The bicomponent spunbond web was not thermally point bonded after it was formed.

The single layer bicomponent spunbond web was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. The pattern roll and anvil roll were heated to a temperature of about 128 degrees Celsius. The pressure in the paddle formed between the pattern roll and the anvil roll was about 56 kg / cm ² . The linear velocity of the bicomponent spunbond web entering the fin was about 20 meters per minute.

Example O

As described in US Pat. No. 5,418,045, the two layer nonwoven laminate material is a continuous bispun spunbond, non-crimped bicomponent filament and a second bicomponent spunbond nonwoven web formed of a continuous meltspun, crimp bicomponent filament Minutes were made using a spunbond nonwoven web. The polymer component of the bicomponent filaments of each nonwoven layer was the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after it was formed. In this example, the basis weights and sizes of the first and second bicomponent spunbond webs forming the bicomponent filaments were different.

After the first bicomponent spunbond nonwoven web of relatively low basis weight and small fiber size is formed, the second bicomponent spunbond nonwoven web of relatively high basis weight and large fiber size is formed to form a top of the first pattern-unbonded nonwoven layer. Was placed in. The second bicomponent spunbond web was temporarily bonded by passing the web through a pin formed between a pair of compacting or pressing rolls rotating in opposite directions. The pressure inside the shock formed by the consolidation roll was about 53 kg / cm ² . The first and second nonwoven layers were laminated together by passing through the pattern-unbonded combination described herein. The pattern-unbonded processing conditions were the same as those mentioned in Example M above. When the peel and shear strength were measured, the second bicomponent spunbond nonwoven web was engaged with the hook member of the measurement hook material.

Example P

As described in US Pat. No. 5,418,045, single layer bicomponent spunbond nonwoven webs were formed of continuous meltspun, uncrimped bicomponent filaments. The polymer constituents of the bicomponent filaments were the same as in the above examples. The bicomponent spunbond web was bonded with a hot air knife placed at a distance of about 28.6 millimeters from the top surface of the web. The air stream exiting the hot air knife was at a temperature of about 118 degrees Celsius. The hot air knife had a sufficient pressure of about 2 millimeters of mercury. The bicomponent spunbond web was not thermally point bonded after it was formed.

The single layer bicomponent spunbond web was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. The pattern-unbonded processing conditions were substantially the same as in Example K above.

Example Q

As described in US Pat. No. 5,418,045, the two layer nonwoven laminate material is a continuous bispun spunbond, non-crimped bicomponent filament and a second bicomponent spunbond nonwoven web formed of a continuous meltspun, crimp bicomponent filament Minutes were made using a spunbond nonwoven web. The polymer component of the bicomponent filaments of each nonwoven layer was the same as in the above examples. The bicomponent spunbond web was not thermally point bonded after it was formed. In this example, the basis weights and sizes of the first and second bicomponent spunbond webs forming the bicomponent filaments were different.

A first bicomponent spunbond nonwoven web of relatively low basis weight and small fiber size was formed and bonded using a hot air knife under the conditions described in Example P above. Thereafter, a second bicomponent spunbond nonwoven web of relatively high basis weight and large fiber size is formed overlying the first pattern-unbonded nonwoven layer and the first and second nonwoven layers described herein are pattern-unbonded. Laminated to each other by passing through a combination. The pattern-unbonded processing conditions were the same as described in Example L above. When the peel and shear strength were measured, the second bicomponent spunbond nonwoven web was engaged with the hook member of the measurement hook material.

Example R

As described in US Pat. No. 5,418,045, single layer bicomponent spunbond nonwoven webs were formed of continuous meltspun, uncrimped bicomponent filaments. The polymer constituents of the bicomponent filaments were the same as in the above examples. The bicomponent spunbond web uses a hot air knife as described above in Example P except that the hot air knife is placed at a distance of about 17.8 millimeters from the surface of the web and the sufficient pressure was about 1.4 millimeters of mercury. Was combined using. The bicomponent spunbond web was not thermally point bonded after it was formed.

The single layer bicomponent spunbond web was formed of a pattern-unbonded nonwoven loop material using the pattern-unbonded combination described herein. The pattern-unbonded processing conditions were substantially the same as in Example K above.

Example S

As described in US Pat. No. 5,418,045 to Piqué et al., Two-layer nonwoven laminate materials were made using different base weight bicomponent spunbond nonwoven webs formed from continuous melt spinning, bicomponent filaments. The polymeric constituents of the bicomponent filaments were present in a weight ratio of 50 to 50 in parallel arrangement. The bicomponent filaments had a substantially circular cross section. The polymer composition comprises: a) 99% polypropylene from Exxon Chemical 3445 and 1% titanium dioxide (TiO ₂ ); and b) 78% linear low density polyethylene (LLDPE) and Shell from Dow 6811A. 10% of KRATON® Table G-2755 polymer from Chemicals, Inc. and 1% of optical bleach sold by Stanridge Chemicals of Social Circle, Inc. as SCC-5348. Kraton table block copolymers include several other compounds identified by US Pat. Nos. 4,663,220, 4323,534, 4,834,735, 5,093,422 and 5,304,559, the many of which are incorporated herein by reference. Commercially available.

The bicomponent spunbond web was then thermally bonded to yield a point bonded nonwoven material having a total bonding area of about 35%.

The sample and comparative materials described above had the following properties.

Example Basis weight (gsm) Fiber size (dfp) Bulk (mils) % Binding area (%) Shear strength (grams) Peel strength (grams) Iterations Comparative Example A 33.9 2.2 20 15 669 321 3 A 33.9 2.2 19 15/36 902 169 3 Comparative Example B 37.3 2.2 22 15 648 229 3 B 37.3 2.2 20 15/36 926 95 3 Comparative Example C 42.4 2.2 20 15 625 188 3 C 42.4 2.2 20 15/36 954 101 3 D 50.9 3.3 25 36 1090 49 3 E 23.7 3.3 11 36 685 236 3 F 33.3 / 33.9 3.3 / 3.3 31 36/36 1710 293 3 G 50.9 / 17.0 7.6 / 2.3 43 36/36 1780 300 3 H 67.8 7.6 38 36 1912 256 3 I 50.9 / 17.0 10.4 / 2.3 44 36 1874 464 10 J 50.9 / 17.0 9.3 / 1.8 42 36 1680 370 3 K 50.9 9.2 35 36 1222 301 10 L 50.9 / 17.0 9.2 / 2.2 50 36 1599 418 10 M 42.4 / 17.0 9.2 / 2.2 38 36 1260 393 10 N 59.3 9.2 41 36 1212 267 10 O 50.9 / 17.0 9.2 / 2.2 50 36 2370 462 10 P 50.9 8.8 25 36 1168 222 10 Q 50.9 / 17.0 8.8 / 2.2 34 36 1607 253 10 R 50.9 8.8 40 36 1504 240 10 S 50.9 / 17.0 6-9 / 2-3 NA 36 5500 1300 6

Although specific values for peeling and shear strength have been presented for the embodiments described above, the pattern-unbonded nonwoven loop material of the present invention is not limited to those values. In general, the pattern-unbound loop material will have a combination of peel and shear strength suitable for the intended end use application. More specifically, the coating strength in the range of about 50 grams to about 500 grams or more is considered suitable for use in the present invention. Likewise, shear strengths in the range of about 600 grams to about 2500 grams or more are considered suitable for use in the present invention. Likewise, the overall basis weight of the pattern-unbound loop material can be selected to be suitable for the intended end use application. Total basis weights in the range of about 20 grams to about 100 grams per square meter, more preferably about 20 grams to about 70 grams, are considered suitable for use in the present invention.

It is contemplated that the pattern-unbonded nonwoven loop material constructed in accordance with the present invention will be tailored and adjusted by one of ordinary skill in the art to accommodate the varying levels of performance requirements imposed during practical use. Therefore, while the present invention has been described by the above embodiments and examples, it should be understood that the present invention is capable of further modifications. Therefore, this application is not intended to adapt to any modification, application or adaptation of the present invention, including departure from the present disclosure as it pertains to the general principles therein and pertains to the known or customary practice to which the invention pertains and which is within the scope of the appended claims. Intended to cover.

Claims (21)

A bulk of at least about 10 mils and a basis of at least about 20 grams per square meter having a fibrous structure of individual fibers or filaments in which at least one portion extends into and is bonded within the discontinuous unbonded region A first nonwoven fabric having a pattern of continuous bonding regions on its surface and having a percent bonding region of about 25% to about 50% having a weight and defining a plurality of discrete unbonded regions formed by thermal and pressure treatment Pattern-unbonded nonwoven comprising a web. The pattern-unbonded nonwoven of claim 1, wherein the nonwoven web has a percent bond area of about 36% to about 50%. The pattern-unbonded nonwoven fabric of claim 1, having a shear strength of at least about 600 grams and a peel strength of at least about 50 grams. The pattern-unbonded nonwoven fabric of claim 1, wherein the nonwoven web comprises a meltspun filament. The pattern-unbonded nonwoven fabric of claim 1, wherein the nonwoven web comprises staple fibers. 5. The pattern-unbonded nonwoven fabric of claim 4, wherein the nonwoven web comprises a meltspun multicomponent filament. The pattern-unbonded nonwoven fabric of claim 1, further comprising a film layer attached to the surface of the nonwoven opposite the surface having a pattern of continuous bond regions defining a plurality of discrete non-bonded regions. The pattern-unbonded nonwoven fabric of claim 1, further comprising a second nonwoven web having a fibrous structure of individual fibers or filaments, wherein the first and second nonwoven webs are laminated together. 9. The method of claim 8 wherein the individual fibers or filaments of the first nonwoven web have a first denier and the second fibers or filaments of the second nonwoven web have a second denier different from the first denier, Wherein the first nonwoven web has a first basis weight and the second nonwoven web has a second basis weight that is different from the first basis weight. One male component; And One magnetic component comprising the pattern-unbonded nonwoven fabric of claim 1 adapted to detachably couple with the male component. Mechanical fastening system comprising a. A disposable absorbent article comprising the pattern-unbonded nonwoven fabric of claim 1. One bodyside liner; One outer cover; One absorbent structure disposed between the liner and the outer cover; A mechanical securing tab comprising one male component connected to the article; And One magnetic component comprising the pattern-unbonded nonwoven fabric according to claim 1 connected to the outer cover and adapted to detachably couple with the male component. Disposable absorbent article comprising a. Forming a first nonwoven web having a fibrous structure of individual fibers or filaments; Feeding the nonwoven web into a fin defined between a first roll having a patterned outer surface and a second roll having a smooth outer surface disposed in an opposite manner; Rotating the first roll and the second roll in opposite directions; Bonding the nonwoven web by heat and pressure treatment to form a pattern of continuous bonding regions defining a number of discrete non-bonding regions on one surface thereof. Including at least one portion of the nonwoven web having a percent bond region of about 25% to about 50% and wherein the individual fibers or filaments within the discontinuous unbonded region extend into and bond within the continuous bond region. A method for producing a pattern-unbonded nonwoven fabric having branches. The method of claim 13, wherein the nonwoven web is fed into the fin defined by the first and second rolls having a patterned outer surface and the nonwoven web is joined by heat and pressure treatment to at least two. Forming a pattern of continuous bonding regions defining a plurality of discrete non-bonding regions on a surface thereof. The method of claim 13, Forming a second nonwoven web having a fibrous structure of individual fibers or filaments; Feed the first and second nonwoven webs into the fin; Joining the first and second nonwoven webs together to form a pattern-unbonded nonwoven laminate Method of producing a pattern-unbonded nonwoven fabric further comprising the step. The method of claim 15, Forming a first nonwoven web having a size of the first fiber or filament and a first basis weight; Forming a second nonwoven web having a second fiber or filament size different from the size of the first fiber or filament and a second base weight different from the first base weight Method of producing a pattern-unbonded nonwoven fabric further comprising the step. 15. The method of claim 13, further comprising temporarily bonding the first nonwoven web. 14. The method of claim 13, further comprising temporarily bonding at least one of the first and second nonwoven webs. 15. The method of claim 13, further comprising forming the nonwoven layer comprising melt spun filaments. 20. The method of claim 19, further comprising forming the nonwoven layer comprising meltspun multicomponent filaments. 21. The method of claim 20, further comprising forming the nonwoven web comprising a meltspun multicomponent filament.